A novel aspect of composite sandwich fairing structure optimization of a two-stage launch vehicle (Safir) using multidisciplinary design optimization independent subspace approach

Abstract

In this article, a novel composite sandwich structure analysis of launch vehicle fairing is considered by a new multidisciplinary design optimization methodology. Among the most important roles of this method, in addition to the convergence of optimization process, is tackling with complicated composite structure discipline. The bidirectional coupling existing between composite structure and trajectory disciplines is one of the complex problems of this multidisciplinary design optimization method. Accordingly, multidisciplinary design optimization based on independent subspaces is employed using the fixed point iteration method to achieve the best convergence at system level and segregate the disciplines. Therefore, the two proposed subspaces overcome the difficulties of common mentioned multidisciplinary design optimization of launch vehicles as the main novelty of this study. The first subspace is a multidisciplinary design optimization which includes propulsion, aerodynamics, weight and trajectory disciplines. The second one includes the novel composite fairing structure optimization as the other single discipline optimization which is analytically and numerically considered as a compact problem and is regarded as the other novelty of this work. In a case study, by applying the proposed architecture on Safir launch vehicle and considering propulsion, trajectory and also composite sandwich fairing structure design as the variables and then performing an optimization process, the Safir fairing mass is reduced from 100 kg to 57.8 kg. This causes the launch vehicle gross mass to decrease from 26 tons to 25.2 tons due to the payload nature of fairing. This 3% mass decrease of an operational launch vehicle, despite the preservation of mission performance, can be called an industrial novelty which leads to the cost reduction of space transportation. The proposed system engineering demonstrates the great importance of using multidisciplinary design optimization in complicated designs using independent subspaces to be employed for the design of future launch vehicles. It can also be a road map for future designers of space vehicles, especially those who want to consider structure optimization in the design loop of launch vehicles.